U.S. patent application number 16/249743 was filed with the patent office on 2019-10-17 for post sleeve positioning apparatus and related methods.
The applicant listed for this patent is N. Eric Knudsen. Invention is credited to N. Eric Knudsen.
Application Number | 20190316379 16/249743 |
Document ID | / |
Family ID | 58361168 |
Filed Date | 2019-10-17 |
![](/patent/app/20190316379/US20190316379A1-20191017-D00000.png)
![](/patent/app/20190316379/US20190316379A1-20191017-D00001.png)
![](/patent/app/20190316379/US20190316379A1-20191017-D00002.png)
![](/patent/app/20190316379/US20190316379A1-20191017-D00003.png)
![](/patent/app/20190316379/US20190316379A1-20191017-D00004.png)
![](/patent/app/20190316379/US20190316379A1-20191017-D00005.png)
![](/patent/app/20190316379/US20190316379A1-20191017-D00006.png)
![](/patent/app/20190316379/US20190316379A1-20191017-D00007.png)
![](/patent/app/20190316379/US20190316379A1-20191017-D00008.png)
![](/patent/app/20190316379/US20190316379A1-20191017-D00009.png)
![](/patent/app/20190316379/US20190316379A1-20191017-D00010.png)
View All Diagrams
United States Patent
Application |
20190316379 |
Kind Code |
A1 |
Knudsen; N. Eric |
October 17, 2019 |
POST SLEEVE POSITIONING APPARATUS AND RELATED METHODS
Abstract
A post sleeve installation system can include a plurality of
post sleeve installation devices and at least one spacing beam or
mechanism. The spacing beam or mechanism can include end portions
that rotate about multiple independent axes and can be coupled to a
pair of post sleeve installation devices to determine or control
the relative locations and orientations between two post sleeves.
The post sleeve installation system can be used to install post
sleeves for posts for a fence, a rail or other structure supported
by posts.
Inventors: |
Knudsen; N. Eric; (Maple
Valley, WA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Knudsen; N. Eric |
Maple Valley |
WA |
US |
|
|
Family ID: |
58361168 |
Appl. No.: |
16/249743 |
Filed: |
January 16, 2019 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
15453725 |
Mar 8, 2017 |
10214940 |
|
|
16249743 |
|
|
|
|
62306988 |
Mar 11, 2016 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
G01B 21/16 20130101;
G01B 5/14 20130101; G01C 5/00 20130101; E04H 12/347 20130101; E04H
17/263 20130101 |
International
Class: |
E04H 17/26 20060101
E04H017/26; G01B 21/16 20060101 G01B021/16; G01B 5/14 20060101
G01B005/14; G01C 5/00 20060101 G01C005/00; E04H 12/34 20060101
E04H012/34 |
Claims
1. A system for positioning post sleeves, the system comprising: a
first post sleeve installation device configured to receive a first
post sleeve; a second post sleeve installation device configured to
receive a second post sleeve; and a spacing mechanism coupleable
between the first and second post sleeve installation devices to
determine or control an elevation of the first post sleeve relative
to the second post sleeve, the spacing mechanism having an
adjustable pitch.
2. The system of claim 1 wherein the spacing mechanism comprises a
spacing beam configured to be coupled at a first end to the first
post sleeve installation device and at a second end to the second
post sleeve installation device.
3. The system of claim 1 wherein the adjustable pitch of the
spacing mechanism enables the spacing mechanism to be oriented at a
plurality of non-zero pitches.
4. The system of claim 1 wherein the spacing mechanism includes a
main body having a first end and a second end opposite the first
end, and wherein the spacing mechanism includes a hinge and a joint
at the first end of the main body.
5. The system of claim 4 wherein the hinge has a horizontal pivot
axis that is perpendicular to a longitudinal axis of the main body,
and wherein the joint has a pivot axis that is perpendicular to the
horizontal pivot axis of the hinge.
6. The system of claim 5 wherein the joint includes a first radial
encoder to sense an angular rotation of the joint and the hinge
includes a second radial encoder to sense an angular rotation of
the hinge.
7. The system of claim 6 wherein the main body includes telescoping
portions and a main body sensor configured to sense a change in
length of the main body.
8. The system of claim 7, further comprising: a controller
configured to receive signals from the first and second radial
encoders and the main body sensor and output data indicative of a
position and an elevation of the first post sleeve installation
device with respect to the second post sleeve installation
device.
9. The system of claim 1 wherein the spacing mechanism includes a
main body having a first end and a second end opposite the first
end, and wherein the spacing mechanism includes a respective hinge
and a respective joint at each of the first and second ends of the
main body, each hinge having a horizontal pivot axis that is
perpendicular to a longitudinal axis of the main body, and each
joint having a pivot axis that is perpendicular to the horizontal
pivot axis of the hinge.
10. The system of claim 1 wherein the first post sleeve
installation device includes a vertical coupling shaft and an end
of the spacing mechanism includes an internal cavity configured to
receive the vertical coupling shaft.
11. The system of claim 10 wherein the vertical coupling shaft has
a bottom end having a cross-sectional shape comprising a first
square and the internal cavity has an opening having a
cross-sectional shape comprising a second square corresponding to
the first square.
12. The system of claim 10 wherein the first post sleeve
installation device includes a plurality of vertical coupling
shafts, and the end of the spacing mechanism is selectively
coupleable to one of the plurality of vertical coupling shafts.
13. A method of installing fence post sleeves, comprising:
installing a first fence post sleeve using an installation device;
and adjusting an elevation of a second fence post sleeve relative
to the first fence post sleeve using the installation device, the
installation device including a spacing mechanism oriented at a
non-zero pitch.
14. The method of claim 13 wherein adjusting the elevation of the
second fence post sleeve includes determining, using a controller,
the elevation of the second fence post sleeve relative to the first
fence post sleeve based on a signal, received by the controller,
corresponding to the non-zero pitch.
15. The method of claim 14, further comprising communicating a
signal corresponding to the elevation of the second fence post
sleeve relative to the first fence post sleeve to a remote
database.
16-18. (canceled)
Description
BACKGROUND
Technical Field
[0001] The disclosed embodiments relate in general to systems for
positioning ground inserts, or post sleeves, in the ground to
receive posts, and in particular to systems for accurately and
repeatably positioning post sleeves relative to the surrounding
terrain and/or adjacent post sleeves.
Description of the Related Art
[0002] Fences are ubiquitous in modern society, used in a vast
range of applications, to mark and accent boundaries, provide
security, and control movement of people and animals. Thousands of
miles of new and replacement fences are installed every year in the
U.S., and utilize vast amounts of construction-related natural
resources.
[0003] FIG. 1 shows a landscape with a fence 100 extending along
portions thereof. The fence 100 shown in FIG. 1 comprises two major
segments, or runs 102. A run is a section or portion of a fence
that extends between natural dividing points such as corners,
gates, buildings, etc. Except where a fence is attached to a
building, each run 102 generally has a main post 104a at each end
and line posts 104 spaced between the main posts. Each pair of
adjacent posts 104 has a fence panel 106 coupled between them. Each
panel 106 comprises horizontal elements, or rails 108, and vertical
elements, or fence boards 110.
[0004] Typically, fence construction and installation involves a
number of steps. In some cases, a site survey is done to determine
the precise location of the fence and to prevent the all-too-common
(and potentially very expensive) occurrence of installing a fence a
few inches or feet beyond the actual property line. A contractor
visits the site to estimate the materials and labor required to
build and install the fence. In addition to simply measuring linear
feet required, elements such as topography and obstructions must be
reviewed and accounted for. If the fence location has not been
marked by the owner or surveyor, the contractor may mark the
location during the initial visit, or during a later visit.
Installation is scheduled, and materials are ordered and delivered
to the site.
[0005] Depending on the scope of the project, the locations and
spacing of the fence posts may be determined and laid out in
advance, by a landscape architect, for example, or left to the
installation crew to determine on site. In either case, the spacing
of the posts is limited by the material available, and typically is
selected to make best use of that material. For example, 96 inch
lumber is commonly used to frame wooden fences, so the maximum
distance between posts cannot exceed 96 inches. On the other hand,
if the contractor uses 96 inch lumber, it would be wasteful to set
the posts 60 inches apart, which would result in about three feet
of waste from every framing rail. However, because of other
considerations, some waste is unavoidable. It is generally
preferable to evenly space the posts of a given run of fence, to
provide an attractive and unified appearance. Inasmuch as such a
run will rarely be evenly divisible by eight feet, each post will
be something less than eight feet apart. Additionally, if the
terrain includes changes in elevation which the bottom and/or top
rail must follow, the length of the angled framing rails between
two posts that are at different heights may be much greater than
the lateral distance between the posts, which reduces the maximum
permissible horizontal distance between any of the posts of that
run. Furthermore, it can be difficult, or at least time consuming,
to precisely position a post to within a fraction of an inch, so a
margin of an inch or two is generally provided. Thus, the posts may
be spaced anywhere from a couple of inches to a couple of feet less
than the maximum allowable distance. Finally, when building fences
from natural materials such a wood, it is not uncommon for
individual pieces to be unsuitable, because of, for example, a knot
in a position that unacceptably weakens a part, or an excessively
warped board, etc. For all of these reasons, some material waste is
expected and allowed for in the original estimate when calculating
the materials for the frame rails, and, for similar reasons, when
calculating materials for fence boards and posts.
[0006] Once the materials and crew are at the site, and with post
locations marked, the post holes are dug, and the posts are
installed. Each post hole may be partially backfilled with gravel
to improve drainage, and the post is then stood in the hole and
held in place by several stakes driven into the ground around the
post and braces of scrap lumber nailed to the stakes and the sides
of the post. A concrete footing is poured into the hole around the
post and allowed to set, and the stakes are later removed. With all
the posts in place and the footings set sufficiently to remove the
braces, frame rails are cut to fit, and attached to the posts,
extending between adjacent posts along the bottom and top of the
fence. Fence boards are then cut to length and attached to the
frame rails. Perfectly parallel and consistently spaced fence
boards along the entire fence run is important, because differences
in spacing will become very obvious to an observer when there is
daylight behind the fence. Because of variations in the spacing of
the posts, it is often necessary to rip fence boards lengthwise to
maintain the correct spacing in some of the panels of a fence run.
Additionally, the lengths of the fence boards may vary
considerably. For example, the ground line between posts can have
obstructions or changes in elevation that the installer adjusts for
in the length of the fence boards in order to maintain a straight
line at the top of the fence while still maintaining proper spacing
or ground clearance at the bottom. Additionally, many fences
include decorative features along the top, such as arches or waves,
in which case the builder may extend the fence boards above the
desired finish line, and cut the fence boards to follow the desired
shape, after installation. The posts are also cut down to the final
length after installation, and post caps or finials are often
attached to the tops. After the fence is installed, it is usually
painted or stained to protect the wood and extend its useful
life.
[0007] If properly executed using good quality material, a fence
that is built and installed as described above can be very
attractive, and can last for many years. However, it will be noted
that there is a significant amount of waste that is produced. Not
only does such waste result in higher material costs, it increases
shipping costs because it must be transported to the site and later
removed, it increases landfill use and fees, and wastes otherwise
valuable resources.
[0008] In view of the expense, labor, and waste associated with
installing a fence that is custom-built on site, another method of
building and installing fences has been introduced.
Pre-manufactured fence panels are becoming more available, and
increasingly can be found in a wide variety of materials, including
wood, vinyl, composite, aluminum, steel, concrete, etc., and in a
wide variety of designs.
[0009] Pre-manufactured panels or kits are typically sold from
retail lumber and hardware outlets. The panels and kits are
provided in standard sizes and are ready for installation. One
common panel size, of the many available, is six feet tall by eight
feet long. The installer digs the post holes at intervals of eight
feet plus the width of a fence post, and places the first post,
with stakes and braces to hold it plumb while the concrete sets, as
described above. However, the installer also attaches the first
fence panel to the post, and may attach the second post to the
first panel at the same time, installing both posts together. The
installer then progresses post-by-post, attaching a panel between
each pair of posts before pouring the footing around the second of
the pair, bracing each post and shimming up each panel to ensure
that the post is held plumb and the fence level until the post
footings are sufficiently hardened, which may be several days
because of the mass of the fence being supported. This process
ensures that the spacing between the posts is correct for the
eight-foot panels. At the end of a fence run, if the last post is
less than eight feet from the previous one, the installer cuts a
fence panel to fit in the remaining space. Alternatively, the
installer may install all of the posts first, but this requires
significant care to ensure that the distance between the posts is
exactly correct. Otherwise, it may be necessary to trim the panel
to fit, or shim the post to fill a gap.
[0010] In contrast to site built fencing, pre-manufactured fence
panels can be produced efficiently, inexpensively, and at a
consistent, predictable quality. Because they are produced in a
manufacturing facility, waste can be significantly reduced, and the
waste that is produced is more likely to be recycled either
internally to produce other products or externally rather than sent
to a landfill. Material handling methods and automated machines for
material optimization allow utilization of all lengths of raw
materials. The factory can obtain lumber that has not been cut to
standard lengths, but is the full length of the log, or stem, from
which it was milled. Scrap that won't work on one fence panel or
design can be diverted and used for another. Flaws and defective
lumber can be detected automatically, and can often be cut out,
allowing the remaining material to be salvaged. This optimization
and defective-material/scrap management process is much more
environmentally friendly than site-built fence processes,
especially as it relates to reducing the production, and increasing
the productive recycling, of waste lumber. As tree trunks don't
come in perfect length increments, the factory can bring in
material in lengths determined by the actual tree trunks and
optimize those random lengths via computer to best utilize the
material, and minimize waste. The panels can be primed or finished
in spray booths or dip tanks in large volumes, using better quality
control, wasting less material, and reducing or eliminating the
environmental impact that arises from on-site finishing.
[0011] Overall, fences built using pre-manufactured fence panels
can be made more efficiently, less expensively, and to higher and
more consistent quality standards, with less waste and less
environmental impact, than fences custom-built on site.
[0012] Further, post sleeve positioning apparatuses and methods
have been developed to facilitate the efficient positioning and
construction of post sleeves, fence posts, and fences. Prior post
sleeve installation devices have included a standing structure, a
structure coupled to the standing structure and configured to
support a post sleeve below the standing structure, and a mechanism
configured to enable selective translation of the support structure
in three axes and rotation around a vertical axis. Locks have been
provided to lock the post sleeve at a selected position and
orientation relative to the standing structure. A beam extending
from one installation device to another has been used to measure or
control the relative spacing, orientation, and elevation of
associated post sleeves, and related data has been collected for
off-site manufacture of fence panels. Additionally, a repository
has been provided, to which the data is transmitted for retention,
and from which the data can be retrieved for manufacture of
replacement fence panels. Examples are described in U.S. Pat. No.
7,861,434, which is hereby incorporated herein by reference in its
entirety.
BRIEF SUMMARY
[0013] The present disclosure describes post sleeve positioning
apparatuses and methods having features and advantages not provided
by prior systems. For example, the present disclosure describes
post sleeve installation devices and spacing beams that can be
coupled to one another to form a post sleeve positioning system in
which the spacing beam can be oriented at any angle with respect to
the post sleeve installation devices. Thus, in the post sleeve
positioning systems described herein, the spacing beam need not be
level during use, and rather can be oriented at any desired pitch
or incline. The post sleeve positioning systems described herein
can be more durable than prior systems and can make the process of
positioning post sleeves, fence posts, and fences more
efficient.
[0014] A system for positioning post sleeves may be summarized as
including: a first post sleeve installation device configured to
receive a first post sleeve and to enable selective adjustment of a
position of the first post sleeve; a second post sleeve
installation device configured to receive a second post sleeve and
to enable selective adjustment of a position of the second post
sleeve; and a spacing mechanism coupleable between the first and
second post sleeve installation devices to determine or control an
elevation of the first post sleeve relative to the second post
sleeve, the spacing mechanism having a variable length and an
adjustable pitch.
[0015] The spacing mechanism may include a spacing beam configured
to be coupled at a first end to the first post sleeve installation
device and at a second end to the second post sleeve installation
device. The adjustable pitch of the spacing mechanism may enable
the spacing mechanism to be oriented at a plurality of non-zero
pitches. The spacing mechanism may include a main body having a
first end and a second end opposite the first end, and the spacing
mechanism may include a hinge and a joint at the first end of the
main body. The hinge may have a horizontal pivot axis that is
perpendicular to a longitudinal axis of the main body, and the
joint may have a pivot axis that is perpendicular to the horizontal
pivot axis of the hinge. The joint may include a first radial
encoder to sense an angular rotation of the joint, and the hinge
may include a second radial encoder to sense an angular rotation of
the hinge. The main body may include telescoping portions and a
main body sensor configured to sense a change in length of the main
body.
[0016] The system for positioning post sleeves may further include
a controller configured to receive signals from the first and
second radial encoders and the main body sensor, and output data
indicative of a position and an elevation of the first post sleeve
installation device with respect to the second post sleeve
installation device.
[0017] The spacing mechanism may include a main body having a first
end and a second end opposite the first end, and the spacing
mechanism may include a respective hinge and a respective joint at
each of the first and second ends of the main body, each hinge
having a horizontal pivot axis that is perpendicular to a
longitudinal axis of the main body, and each joint having a pivot
axis that is perpendicular to the horizontal pivot axis of the
hinge. The first post sleeve installation device may include a
vertical coupling shaft, and an end of the spacing mechanism may
include an internal cavity configured to receive the vertical
coupling shaft. The vertical coupling shaft may have a bottom end
having a cross-sectional shape comprising a first square, and the
internal cavity may have an opening having a cross-sectional shape
comprising a second square corresponding to the first square. The
first post sleeve installation device may include a plurality of
vertical coupling shafts, and the end of the spacing mechanism may
be selectively coupleable to one of the plurality of vertical
coupling shafts.
[0018] A method may be summarized as including: installing a first
fence post sleeve using an installation device; adjusting an
elevation of a second fence post sleeve relative to the first fence
post sleeve using the installation device, the installation device
including a spacing mechanism oriented at a non-zero pitch; and
fixing the elevation of the second fence post sleeve relative to
the first fence post sleeve.
[0019] Adjusting the elevation of the second fence post sleeve may
include determining, using a controller, the elevation of the
second fence post sleeve relative to the first fence post sleeve
based on a signal, received by the controller, corresponding to the
non-zero pitch.
[0020] The method may further include communicating a signal
corresponding to the elevation of the second fence post sleeve
relative to the first fence post sleeve to a remote database.
[0021] A method may be summarized as including: installing a first
fence post sleeve; installing a second fence post sleeve; and
determining an elevation of the second fence post sleeve relative
to the first fence post sleeve with a installation device including
a spacing mechanism oriented at a non-zero pitch.
[0022] Determining the elevation of the second fence post sleeve
relative to the first fence post sleeve may include adjusting the
pitch of the spacing mechanism.
[0023] The method may further include communicating a signal
corresponding to the elevation of the second fence post sleeve
relative to the first fence post sleeve to a remote database.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0024] FIG. 1 shows a landscape with a fence.
[0025] FIG. 2 shows a known post sleeve positioning system
including a pair of post sleeve installation devices and a level
spacing beam.
[0026] FIG. 3 shows a perspective view of elements of one of the
post sleeve installation devices of FIG. 2, showing position
control and lock mechanisms for x, y, and z axes and
orientation.
[0027] FIG. 4 shows a plan view of elements of the post sleeve
installation device of FIG. 3, showing additional details of the
position control and lock mechanisms.
[0028] FIG. 5 shows a perspective view of z-axis and orientation
control and lock mechanisms of another known post sleeve
installation device.
[0029] FIG. 6 shows a post sleeve attachment mechanism and quick
release mechanism of the post sleeve installation device of FIG.
3.
[0030] FIG. 7 shows the spacing beam of the post sleeve positioning
system of FIG. 2.
[0031] FIG. 8 shows a detailed view of a coupling mechanism of the
spacing beam of FIG. 2.
[0032] FIG. 9 shows a post sleeve installation device for use in a
post sleeve positioning system, according to at least one
illustrated embodiment.
[0033] FIG. 10 shows components of the post sleeve installation
device of FIG. 9 at a larger scale, according to at least one
illustrated embodiment.
[0034] FIG. 11 shows a spacing beam for use with the post sleeve
installation device of FIG. 9, according to at least one
illustrated embodiment.
[0035] FIG. 12 shows a top perspective view of components of the
spacing beam of FIG. 11 at a larger scale, according to at least
one illustrated embodiment.
[0036] FIG. 13 shows a bottom perspective view of components of the
spacing beam of FIG. 11 at a larger scale, according to at least
one illustrated embodiment.
[0037] FIG. 14 shows another top perspective view of components of
the spacing beam of FIG. 11 at a larger scale, according to at
least one illustrated embodiment.
[0038] FIG. 15 shows an image of components of the spacing beam of
FIG. 11, according to at least one illustrated embodiment.
[0039] FIG. 16 shows a user interface for use with the systems
described herein, according to at least one illustrated
embodiment.
DETAILED DESCRIPTION
[0040] In the following description, certain specific details are
set forth in order to provide a thorough understanding of various
disclosed embodiments. However, one skilled in the relevant art
will recognize that embodiments may be practiced without one or
more of these specific details, or with other methods, components,
materials, etc. In other instances, well-known structures
associated with the technology have not been shown or described in
detail to avoid unnecessarily obscuring descriptions of the
embodiments.
[0041] Unless the context requires otherwise, throughout the
specification and claims that follow, the word "comprising" is
synonymous with "including," and is inclusive or open-ended (i.e.,
does not exclude additional, unrecited elements or method
acts).
[0042] Reference throughout this specification to "one embodiment"
or "an embodiment" means that a particular feature, structure or
characteristic described in connection with the embodiment is
included in at least one embodiment. Thus, the appearances of the
phrases "in one embodiment" or "in an embodiment" in various places
throughout this specification are not necessarily all referring to
the same embodiment. Furthermore, the particular features,
structures, or characteristics may be combined in any suitable
manner in one or more embodiments.
[0043] As used in this specification and the appended claims, the
singular forms "a," "an," and "the" include plural referents unless
the context clearly dictates otherwise. It should also be noted
that the term "or" is generally employed in its broadest sense,
that is, as meaning "and/or" unless the context clearly dictates
otherwise.
[0044] As noted above, pre-manufactured fence panels provide a
number of benefits over conventional site-built fences.
Nevertheless, they are not widely used, especially by commercial
fence builders. A fundamental problem that prevents wider adoption
of pre-manufactured fence panels is that they are not manufactured
for specific locations, but are made to standard sizes, so the user
does not have the option of using non-standard post spacing.
Because the spacing must conform to a standard, a shorter, custom
length panel is almost always required at one of the ends of a run,
which can result in an unbalanced appearance and detract from the
appearance of the finished fence. Further, the process of making
the custom length panel on site can add to the waste factor.
Additionally, a typical pre-manufactured fence panel can only be
installed to extend perpendicular to a vertical post, so it cannot
follow a change in elevation. The installer is obliged to
stair-step the panels, as illustrated in the run 102 of FIG. 1,
rather than "racking" the rectangular shape to become a
parallelogram roughly following the topography. Furthermore, stair
stepping generally results in a gap under the fence at the low side
of each panel, which may require that some extension be added to
the bottoms of the panels to fill the gaps. These options may not
be acceptable to the end user, especially when the end user is
paying the higher cost that a typical site-built fence commands.
Finally, commercial installers generally find it more efficient to
install all of the posts first, and then install the structural
stringers and fence boards. Because of the difficulty in spacing
and elevating the posts with sufficient accuracy for
pre-manufactured panels, and the resulting extra expense entailed
in more careful spacing, or reworking a panel when the spacing is
not correct, commercial fence contractors often avoid
pre-manufactured fence panels.
[0045] With a more reliable and efficient mechanism for accurately
positioning fence posts during installation, pre-manufactured fence
panels would be more widely acceptable. Additionally, if custom
fence panels could be built in a factory setting, they would
benefit from many of the same advantages that are associated with
the pre-manufactured commodity panels, which are typically
available only in standard styles and sizes. Thus, as noted above,
some existing post sleeve positioning apparatuses and methods have
been developed to facilitate the efficient positioning and
construction of post sleeves, fence posts, and fences.
[0046] For example, systems are known for selectively positioning
post sleeves in the ground, each sleeve being configured to receive
a respective fence post, such as the systems disclosed in U.S. Pat.
No. 7,861,434, which is hereby incorporated herein by reference in
its entirety. In addition, post sleeves are disclosed, for example,
in U.S. Pat. No. 8,011,149, and entitled "Post Sleeve Assembly,"
which is also incorporated herein by reference in its entirety.
Post sleeves are devices that are configured to be permanently
fixed in the ground at the location of a fence or sign post, and
into which the post is later positioned. Once a post sleeve is set
in the ground, the precise position and depth of the post is fixed,
and therefore the relative positions and orientations of adjacent
posts are also fixed, by respective post sleeves, before the posts
are emplaced. Accordingly, the dimensions of a fence panel that is
to be installed between two adjacent posts can be determined, from
the relative positions and orientation of the post sleeves, to a
degree sufficient to manufacture the panel offsite, with confidence
that the panel will properly fit between the posts that are
eventually placed in the sleeves. Finally, if the position and
orientation of the post sleeves of a fence can be adequately
controlled during installation, the dimensions of each of the fence
panels can be planned in advance, so that the posts and fence
panels can be ready for installation when the post sleeves are
installed.
[0047] By way of additional background, FIG. 2 shows a known post
sleeve positioning system 200. The system 200 includes a plurality
of post installation devices, or "spider frames" 202a, 202b, and a
spacing beam 204 having first and second ends 205, 207. Hereafter,
except where it is necessary to distinguish between spider frames
202a and 202b of FIG. 2, they will be referred to simply by
reference number 202.
[0048] Each spider frame 202 is configured to suspend a post sleeve
206 in a post hole in a position that is minutely adjustable in
three axes and around a longitudinal axis. The spacing beam 204,
when coupled to extend between two spider frames 202 supporting
respective post sleeves, is configured to determine or control the
relative positions and orientations of the post sleeves 206.
[0049] Using at least two spider frames 202 and a spacing beam 204,
a user can install post sleeves in preselected positions, relative
to each other, well within acceptable tolerances for offsite
production of custom pre-manufactured fence panels and
cut-to-length posts, for future installation by others. By
leapfrogging two or more spider frames 202, as will be described
later in more detail, a user can similarly install any number of
post sleeves.
[0050] Each spider frame 202 comprises a leg assembly 208, a column
assembly 210, and a position assembly 212. The leg assembly 208
supports the spider frame 202 and includes a plurality of legs 214
with adjustable feet 216 by which the spider frame 202 can be
positioned level over a post hole, regardless of the terrain. As
shown on the spider frame 202a, the legs 214 each include an inner
telescoping sleeve 215 to accommodate extreme slopes. Spirit vials
218 are attached to an upper surface of the leg assembly 208 to
facilitate leveling. Adjustment knobs 220 at the top of each leg
214 are coupled to an extension mechanism of the respective leg.
Using a standard cordless drill with a driver insert, the user can
engage a socket provided in each knob 220 to adjust the length of
the respective leg 214. Rotation of the knob 220 in one direction,
e.g., clockwise, extends the respective foot 216 and lengthens the
leg, while rotation of the knob in the opposite direction retracts
the foot 216 and shortens the leg. The knobs can also be manually
rotated. In alternative implementations, motors or actuators are
provided in the spider frame to control the leg lengths. Handles
221, shown on spider frame 202, are provided to simplify moving and
lifting of the spider frame. At least two of the legs 214 can be
provided with lockable wheels to permit a single installer to move
the spider frame "wheelbarrow" style.
[0051] Turning to FIG. 3, the column assembly 210 and portions of
the position assembly 212 are shown. The position assembly 212
includes a column assembly bearing block 232 with a cylindrical
aperture 234 extending therethrough parallel to the Z axis and two
guide channels 235 extending parallel to the X axis. A pair of
guide shafts 236 are positioned in respective ones of the guide
channels 235 with a pair of Y axis racks 240 extending between the
guide shafts at respective ends. The column assembly 210 is
supported by the bearing block 232, which in turn is coupled to the
leg assembly 208 via the guide shafts 236. The ends of guide shafts
236 engage respective Y-axis bushings 250 that are positioned in
slots formed in the leg assembly 208, permitting the guide shafts
236, with the bearing block 232 and column assembly 210, to
translate in the Y axis. A
[0052] Y-axis lock 252 is coupled to the leg assembly 208 and
includes a rack engagement block 254 configured to engage the teeth
of one of the Y-axis racks 240, in order to lock the guide shafts
236 in the Y axis. A pneumatic piston 256 is configured to
disengage the Y-axis lock 252 when activated. The position assembly
212 also includes mechanism for locking the position of the column
assembly in the X and Z axes and orientation. These mechanisms are
shown and described in more detail later.
[0053] The column assembly 210 comprises a Z-axis index 222, a
Z-axis spacer 226, and a post sleeve support assembly 228 (see FIG.
6). The Z-axis index 222 has four vertical faces 229, each of which
is provided with a pair of longitudinal slots 225 and an elevation
scale 223 between the slots. Adjustable support saddles 227
slidably engage the longitudinal slots 225, and are configured to
receive an end of the spacing beam 204, which will be described
later. The Z-axis index 222 is rigidly coupled to one end of the
Z-axis spacer 226, while the post sleeve support assembly 228 is
rigidly coupled to the other end of the Z-axis spacer. Thus, the
distance and orientation of the post sleeve support assembly 228
remains fixed with respect to the Z-axis index 222. The Z-axis
spacer 226 extends through the aperture 234 of the column assembly
bearing block 232 so that a portion of the column assembly is above
the bearing block and a portion is below. The Z-axis spacer 226 is
translatable in the Z axis and rotatable around a longitudinal axis
that lies parallel to the Z axis, within the aperture 234 of the
column assembly bearing block 232. A Z-axis control 268 is provided
(see FIG. 5) that locks the column assembly 210 in the Z-axis and
in orientation, relative to the bearing block 232.
[0054] Turning to FIGS. 4 and 5, elements of the position assembly
are described in more detail. FIG. 4 shows the position assembly
212 in plan view, with outlines of the leg assembly 208 and the
column assembly bearing block 232 provided in dashed lines to show
relative positions. Also shown are the locations of slots 251 in
which the Y-axis bushings 250 are positioned to permit translation
of the bearing block 232 and column assembly 210 in the Y axis. The
Z-axis spacer 226 is positioned in the cylindrical aperture 234,
and includes a longitudinal aperture 231 through which a portion of
the Z-axis control 268 extends.
[0055] The bearing block 232, with the column assembly 210, slides
along the guide shafts 236 in the X axis. X-axis bushings 258 are
provided in the guide apertures 235 to facilitate movement of the
bearing block 232 along the guide shafts 236 without undue play. An
X axis rack 237 is coupled to one of the guide shafts. An X-axis
lock 260 is coupled to the bearing block 232 and comprises a rack
engagement block 262 configured to engage the teeth of the X-axis
rack 237, in order to lock the bearing block 232 in the Y axis. A
pneumatic piston 264 is configured to disengage the X-axis lock 260
when activated.
[0056] FIG. 5 shows, in perspective view, the position assembly 212
and portions of the column assembly 210. The bearing block 232 and
the Z-axis spacer 226 are shown in dashed lines for reference. The
Z-axis control 268 includes a Z-axis lift bracket 380, a lead screw
382, and a Z-axis drive. The Z-axis lift bracket 380 is coupled to
the bearing block 232 and cantilevers into the longitudinal
aperture 231 of the Z-axis spacer 226, which extends for a
substantial portion of the length of the spacer. The shape of the
Z-axis lift bracket 380 and the width of the longitudinal aperture
231 cooperate to permit rotational adjustment of the column
assembly 210 across a significant range. For example, the column
assembly 210 can be rotated about 20-25 degrees in either direction
from center. Provided the installer is able to orient the spider
frame 202 to within about 20 degrees of the correct orientation,
the column assembly 210 can be precisely adjusted to the desired
orientation. The lead screw 382 is coupled to a plate at the bottom
of the Z-axis spacer 226 and extends axially within the spacer and
through an aperture in the Z-axis lift bracket 380. The Z-axis
drive is mounted to the Z-axis lift bracket 380 and engages the
lead screw 382. Although not shown in detail, the Z-axis drive
operates in a manner similar to the worm drive 330 described with
reference to FIG. 7. A drive input shaft is provided for operation
of the Z-axis drive, which, moves the column assembly in the Z
axis, relative to the bearing block 232. The drive input shaft is
provided with a socket that is configured to receive a drive key,
and can be operated using a common cordless drill.
[0057] An orientation lock 390 is coupled to the Z-axis lift
bracket 380 inside the Z-axis spacer 226, and includes a brake shoe
392, pivotably coupled to the lift bracket, and a pneumatic
actuator 394 that is rigidly coupled to the lift bracket via an
actuator mount that is not shown. A spring pulls the brake shoe 392
down into engagement with the inner surface of the Z-axis spacer
226, effectively locking rotation of the column assembly 210. When
the actuator 394 is activated, it pushes upward on the brake shoe
392 to disengage it from the spacer and permit rotational and
Z-axis adjustment of the column assembly 210.
[0058] FIG. 6 shows the lower end of the Z-axis spacer 226 and the
post sleeve support assembly 228. The post sleeve support assembly
228 includes an exterior casing 290, shown partially cut away to
show details of a sleeve lift lock 292. The support assembly is
also shown separated from the lower end of the Z-axis spacer 226 to
better illustrate a quick release mechanism 300, by which the
support assembly can be easily coupled and decoupled with the
Z-axis spacer 226 allowing attachment of other devices such as bolt
pattern plates or removable post hole molds. The lift lock 292
includes a pair of lift latches 296 configured to engage respective
notches on inner surfaces of a post sleeve via slots 298 in the
casing 290, in order to couple the sleeve to the post sleeve
support assembly 228. A pneumatic cylinder 295 is configured to
withdraw the latches into the casing to release the post sleeve. A
manual release is also provided, comprising a section of braided
wire coupled to the lift lock and extending to a pull-ring outside
the upper end of the post sleeve support assembly 228.
[0059] The quick release mechanism 300 is provided to couple the
post sleeve support assembly 228 to the Z-axis spacer 226. The
quick release mechanism 300 includes a pair of support bars 302
coupled to the upper portion of the post sleeve support assembly
228, and engagement notches 304, a spring latch 306, and a release
handle 308 coupled to the lower end of the Z-axis spacer 226. To
couple the post sleeve support assembly 228 to the Z-axis spacer
226, the user first positions one of the support bars 302 in the
engagement notches 304, then applies upward force to the post
sleeve support assembly until the spring latch 306 engages the
other of the support bars 302. To release the post sleeve support
assembly 228, the user presses the release handle 308, which
disengages the spring latch 306 from its support bar 302,
permitting the other support bar to disengage from the engagement
notches 304.
[0060] For operation of the various pneumatic devices described
above, the spider frame 202 can be provided with an onboard source
of pressurized air, as described later in an alternate design, or
can include a pneumatic connector configured to receive pressurized
air from an external source, such as from a compressor, storage
tank, etc.
[0061] In operation, a user first attaches a post sleeve to the
spider frame 202. This can be done by engaging the post sleeve
support assembly 228 in a post sleeve, then coupling the
quick-release mechanism 300, with the spider frame standing on
buckets or saw horses, or otherwise somewhat elevated to provide
sufficient clearance. The user, preferably with a helper, then
positions the spider frame 202 over a previously prepared post
hole. The user adjusts the legs 214 until the spider frame 202 is
level and stable, referring to the spirit vials 218 to find the
level position. The user then releases the Y-axis lock 252 by
applying air pressure to the pneumatic piston 256, and moves the
column assembly 210 in the Y axis until it is correctly positioned,
then releases the air pressure from the piston 256, which locks
movement in the Y axis. The user then releases the X-axis lock 260
by applying air pressure to the pneumatic piston 264, and moves the
column assembly 210 in the X axis until it is correctly positioned,
then releases the air pressure from the piston 264, which locks
movement in the X axis. Alternatively, the user can release both X-
and Y-axis locks simultaneously and move the column assembly freely
in both axes, then, when the assembly is properly position, engage
both locks again.
[0062] Having positioned the post sleeve in the X and Y axes, the
user then activates the pneumatic actuator 394 to free the rotation
lock 390 and the Z-axis control 268. Operation of the Z-axis drive
moves the column assembly, with the post sleeve attached, in the
Z-axis, and orientation can be simultaneously adjusted. When the
actuator 394 is released, the brake shoe 392 again engages the
Z-axis spacer 226, rotationally locking the column assembly.
[0063] With the post sleeve correctly positioned, the user
back-fills the post hole with concrete or other hardenable material
around the post sleeve. When the concrete or other hardenable
material has set sufficiently to hold the post sleeve in position,
the user releases the lift lock 292 to separate the post sleeve
support assembly 228 from the sleeve, and raises the column
assembly 210 until the post sleeve support assembly 228 is out of
the sleeve. The user can then move the spider frame from its
position over the post hole, and repeat the installation steps to
install additional sleeves.
[0064] In some instances, the sleeve can be placed in the hole
first, then the spider frame placed over the hole and the sleeve
engaged while in the hole. In the event there is no "partner" to
assist, this is a desired method, due to the weight concerns.
[0065] While various mechanisms have been disclosed as being
actuated by pneumatic pistons that are configured to disengage
their respective locking mechanisms or provide z axis control,
other control and locking systems can be used. Examples include
manually operated locks, such that the user engages and disengages
the locks by rotating respective levers or latches, locks operated
by automatically or manually entering a desired position into a
control circuit, sensors provided at various locations to detect
the position and orientation of the column assembly, or servomotors
controlled to reposition the column assembly to the desired
position and orientation. The spider frame can also be
self-leveling.
[0066] Sensors such as are well known in the art detect the degree
of correction required to level the frame, and activate
servomotors, pistons, or the like, to extend or retract the feet as
necessary.
[0067] Turning to FIG. 7, the spacing beam 204 is shown with
portions cut away to show internal detail. The spacing beam 204
includes a hollow casing 310, an extension arm 312, an extension
mechanism, 314, a fixed arm 316, and first and second mounting
fixtures 318. The hollow casing 310, the extension arm 312, and the
fixed arm 316 are formed from materials that are selected to be
substantially rigid and lightweight, such as, for example, aluminum
extrusion, fiberglass, carbon fiber, structural foam, etc. The
hollow casing 310 includes a handle section 320 that incorporates
electronic control circuitry, the operation of which will be
described later. The extension arm 312 is configured to slide
telescopically within the hollow casing 310. The first mounting
fixture 318 is coupled to a first end 336 of the extension arm 312,
which also corresponds to the first end 205 of the spacing beam. A
drive nut 322 is coupled to a second end 338 of the extension arm
312, inside the casing 310. Scale markings 324 along the top of the
extension arm 312 indicate, at the point where the extension arm
enters a first end 341 of the hollow casing 310, a total length of
the spacing beam 204.
[0068] The extension mechanism 314 includes a mounting plate 326, a
worm drive 330, and a threaded drive rod 328 coupled to the
mounting plate via a bearing block 344, and having a worm gear of
the worm drive fixed thereto. A drive input shaft 332 is coupled to
a worm of the worm drive 330, which engages the worm gear for
rotation of the drive rod 328. An encoder 334 is mounted on the
mounting plate and coupled to an end of the drive rod 332 to detect
and meter rotation of the drive rod relative to the casing 310. The
mounting plate 326 is rigidly coupled to the casing 310, with the
drive rod extending longitudinally within the casing and the drive
input 332 extending from the casing via an aperture. The drive rod
328 engages the drive nut 322 of the extension arm 312 inside the
casing 310 such that rotation of the drive rod extends or retracts
the extension arm, according to the direction of rotation. The
drive input shaft 332 is provided with a socket that is configured
to receive a drive key, and can be operated using a common cordless
drill. In other instances, a servo motor is provided, configured to
rotate the threaded drive rod 328, the drive nut 322, or the drive
input 332 to extend and retract the extension arm 312.
[0069] The fixed arm 316 is rigidly coupled to the hollow casing
310 and extends a short distance from a second end 342 of the
casing. The second mounting fixture 318 is coupled to the portion
of the fixed arm 316 that extends from the casing 310, at the
second end of the spacing beam 204.
[0070] The first and second mounting fixtures 318 may be
substantially identical, and one is shown partially exploded in
FIG. 7. Each mounting fixture 318 includes a hinge knuckle 350 that
is rigidly coupled to one of the fixed or extension arms 316, 312.
The hinge knuckle 350 is rotatably coupled to a mounting bracket
354 by a coupling pin 352. An encoder is mounted in the hinge
knuckle 350 and coupled to the coupling pin 352 to detect and meter
rotation of the hinge knuckle 350 relative to the mounting bracket
354. The mounting brackets 354 also include a scale 358 indicating
degrees of rotation, and an indexing pointer 356 is provided on the
end of the respective arm 316, 312, positioned to indicate on the
scale 358 the angle of the spacing beam 204 relative to the
mounting bracket 354. Spirit vials 360 are provided on the fixed
and extension arms 316, 312 and configured to be centered when the
spacing beam 204 is in a level position. The mounting brackets 354
are configured to be coupled to an index face 229 of the column
assembly 210 of the respective spider frame 202, as described in
detail with reference to FIG. 8.
[0071] In some instances, a metering circuit may be provided in the
handle section 320, and coupled to the encoder 334 of the extension
mechanism 314 and the encoders of the first and second mounting
fixtures 318. The metering circuit is configured to determine, from
the signal provided by the encoder 334 the position of the
extension arm 312 relative to the casing 310, and thus the overall
length of the spacing beam 204. From signals provided by the
encoders, the metering circuit determines the angle of each of the
mounting brackets 318 relative to a longitudinal axis of the
spacing beam 204. The electronic system can also include an
electronic level with a digital readout indicating the angle of the
beam, and can provide an audible signal when the beam is level,
which relieves the installer of the necessity to refer to a spirit
vial while adjusting the beam.
[0072] When the spacing beam 204 is level and coupled to extend
between two spider frames 202, as shown in FIG. 2, the precise
distance between the two spider frames is equal to the length of
the beam, which is indicated by the scale markings 324 on the
extension arm 312, the relative orientations of the column
assemblies 210 of the respective spider frames is reflected by the
angles of the mounting brackets 354 relative to the axis of the
beam, and the difference in elevation is obtained by reference to
the elevation scales 223 on the index faces 229 to which the
respective mounting brackets 354 are coupled, as discussed
below.
[0073] Turning to FIG. 8, a detail of FIG. 2 is shown, indicated in
FIG. 2 by dashed circle 9. FIG. 8 shows the second end 207 of the
spacing beam 204, including the fixed arm 316 and the second
mounting fixture 318, with the mounting bracket 354 coupled to a
saddle 227, which in turn is slidably engaged to the longitudinal
slots 225 of one of the faces 229 of the Z-axis index 222. A second
saddle 227 is shown in exploded view, coupled to an adjacent face
229. The saddle 227 includes a locking plate 345 that is captured
between facing pairs of the longitudinal slots 225 so as to be
slidable along the face of the Z-axis index 222, but not removable.
The locking plate 345 has a threaded aperture 347 that is engaged
by a tensioning knob 349. The tensioning knob 349 includes a
threaded connector 351 that traverses an aperture 353 in the saddle
227 and engages the threaded aperture 347 in the locking plate 345.
While the tensioning knob 349 is loose, the locking plate 345 can
slide along the longitudinal slots 225, but when the user tightens
the tensioning knob 349, the saddle 227 and locking plate 345
cooperate to lock the saddle in position.
[0074] A locking pin 370 of the mounting bracket 354 engages a
transverse aperture 355 in the saddle 227 and corresponding
apertures in the mounting bracket 354 to form a hinged coupling
between the mounting bracket and the saddle, which permits one end
of the spacing beam 204 to be coupled to a spider frame 202 as the
user raises the other end until the spacing beam is level. The
elevation of the mounting bracket 354 on the Z-axis index 222 can
be read from the scale 223 adjacent to the top surface of the
mounting bracket.
[0075] It will be recognized that the value indicated on scale 223
has no relation to the elevation of the mounting bracket relative
to the bearing block 232 or the leg assembly 208, or even,
directly, to the ground on which the spider frame 202 is
positioned. Instead, the value is directly related to the distance
of the mounting bracket from the post sleeve coupled to the column
assembly 210.
[0076] Thus, the difference in values indicated at the first and
second mounting brackets 354 of the spacing beam 204, coupled to
respective spider frames 202, represents the difference in
elevation between the respective post sleeves. If the mounting
bracket 354 that is coupled to the higher of the two spider frames
is aligned with the zero position at the bottom of the
corresponding scale 223, the value indicated at the opposite
mounting bracket will be the actual difference in elevation between
the post sleeves. Otherwise, it is a simple matter of subtraction
to obtain the correct value.
[0077] The hinge knuckle 350 of the mounting fixture 318 is
provided with an additional encoder that is configured to read the
scale 223 of the Z-axis index 222 and provide a signal
corresponding to the vertical position of the mounting bracket 318
on the index, and the metering circuit is configured to derive a
relative elevation difference of the post sleeves on the basis of
signals from encoders at the first and second ends 205, 207 of the
spacing beam, to establish the relative elevation difference.
[0078] Laser distance finders are coupled to the ends of the
spacing beam 204 in proximity to the coupling pin 352, and
configured to provide a signal corresponding to a distance from the
mounting bracket to a plate at the base of the Z-axis index, from
which the elevation difference can be derived.
[0079] Installation of a number of post sleeves, for a fence run,
for example, will now be described with reference to FIG. 2. To
differentiate between the elements of the spider frames 202a and
202b in the description, references to elements of the spider frame
202a will include the character "a," while references to elements
of the spider frame 202b will include the character "b."
[0080] The basic layout of the fence is first established. This
generally involves determining the location of the main posts, and
the appropriate spacing between the line posts. A fence line is
then established. This is traditionally done by running a string
line parallel to the fence line some short specific distance away,
which permits the installer to build the fence without interfering
with the line, but having the line available for reference. It is
becoming more common for a contractor to use a laser plane
projector, such as is used in many of the construction trades, to
project a vertical plane along the fence line. The installer starts
at the far end and works toward the projector, using the vertical
line projected by the device to align the fence.
[0081] To install a number of post sleeves, an installer user first
provides post holes at the general locations where the post sleeves
are to be installed. A first post sleeve 206 is positioned in the
X, Y, and Z axes using a first spider frame 202a, substantially as
described above. The spider frame 202a is locked in orientation and
all axes, oriented and aligned with the centerline of the fence
line. The footing of the first post sleeve is then poured.
[0082] A second spider frame 202b is positioned over the adjacent
post hole with a second post sleeve attached. The second spider
frame 202b is leveled and the second post sleeve is correctly
positioned in the Z axis. The second spider frame 202b is locked in
the z axis only, being otherwise free to move and rotate.
Evaluating the two post sleeves, the installer determines which is
at a higher elevation, which, in FIG. 2, is the sleeve of spider
frame 202b. Using support saddles 227 on the most nearly mutually
facing faces 229 of the Z-axis indexes 222 of the spider frames
202a, 202b, the installer sets the higher sleeve's saddle 227 to
the zero position, and sets the opposing saddle 227 to
approximately or exactly the same elevation. This can be done with
a laser level or vial level, etc. The spacing beam 204 is then set
to the desired length, and its first end 205 is coupled to the
saddle 227 of the first spider frame 202a. With the X and Y axes
and rotation of the second spider frame 202b unlocked, the second
spider frame 202b is manipulated until the second end of the
spacing beam can be coupled to the saddle 227 of the second spider
frame 202b. The level of the spacing beam 204 is adjusted, if
necessary, by moving the mounting bracket of the lower (202a) of
the spider frames until the beam is perfectly level.
[0083] The second spider frame 202b is then brought into proper
alignment with, and centered on, the fence line, with the column
assembly 210b floating in the X and Y axes and rotation, to permit
alignment and any final adjustments of the beam length. With the
spacing beam 204 set and level, and the column assembly 210b
correctly positioned in the X and Y axes and in orientation, the
installer engages the respective locks, then pours the footing of
the second post sleeve.
[0084] If the post sleeves are being installed to a prepared plan
that sets forth specific values, the values will have been
confirmed before and after the footing is poured, and are thus
known. If the sleeves are being installed according to a more
general plan, in which, for example, the distances between fence
posts have been substantially predetermined, but other parameters
are to be established on site, data from the spider frames and
spacing beam is collected immediately after the footing is poured,
including distance, relative orientation, and relative
elevation.
[0085] One of the advantages provided by the aforementioned systems
is that post sleeves can be installed according to very precise
position and orientation requirements. This is advantageous when
using fence panels that are manufactured before the sleeves are
installed, because the size and shape of the panels are already
fixed. However, another advantage is that, where the fence panels
will be manufactured after sleeve installation, sleeves can be
installed with a certain degree of latitude, because, however
inexact the installation may be, the exact values of the relative
positions and orientations of the sleeves are obtained once the
sleeves are emplaced. This permits an installer to work much more
quickly than would be possible when installing to very precise
values, while still being able to obtain accurate values for the
manufacturer of the panels.
[0086] Each post sleeve may be provided with a unique identifier
(UI). This can be a factory-installed serial number (e.g., a 5
digit alphanumeric serial number), barcode, or reference marking,
which can be printed, embossed, or otherwise placed on the post
sleeve or on the footing as the sleeve is installed, some reference
marking on a plat map, GPS coordinates, etc. In some cases, the
unique identifier can be provided by an RFID device within the post
sleeve. In any case, these identifiers are recorded with the
collected data so that the correct fence panel can be manufactured
and installed. Each post to be installed within a respective fence
post sleeve can be provided with its own unique identifier matching
the unique identifier of the fence post sleeve within which it is
to be installed. Each fence panel to be installed between two fence
posts can be provided with its own unique identifier, which can be
a combination of the unique identifiers for the fence posts between
which it is to be installed (e.g., the unique identifiers for the
fence posts can be combined and separated by a hyphen). The order
in which the unique identifiers for the fence posts are combined
can signify the orientation of the fence panel in the field. For
example, the fence panel can be oriented in the field so that its
right side, when viewed from the fence post of the first unique
identifier to the fence post of the second unique identifier, faces
outward with respect to a fenced-in region (or in an alternative
implementation, inward).
[0087] Once the data has been collected, the user decouples the
spacing beam 204 from the first and second spider frames and
repeats the process by positioning a third post sleeve coupled to a
third spider frame in a hole prepared adjacent to the second post
sleeve, with the second spider frame now fixed in position and the
third spider frame being adjusted accordingly.
[0088] An installer may work with as few as three or four spider
frames, while all but the shortest fences will have many more posts
to be installed. Accordingly, once the available spider frames have
been used, the user tests the oldest of the footings for firmness
of the concrete, and when safe, moves that spider frame to the
newest hole. Depending on how fast the concrete sets and how fast
the installer works, it may be necessary to use three to six spider
frames to efficiently install any number of post sleeves,
leapfrogging each from the back of the line to the front as the
concrete in each hole sets.
[0089] As each post sleeve is positioned, data necessary to
manufacture a fence panel for that location is collected from the
spacing beam 204, including the exact distance between the post
sleeves, the relative orientation of the post sleeves, and the
relative elevation of the post sleeves.
[0090] The data can be collected in a number of different ways. For
example, the installer can merely read the values from the spacing
beam 204 and Z-axis index, and write them down or enter them into a
recording device. Alternatively, the spacing beam 204 can be
provided with a metering device that includes a transmitter,
configured to transmit the relevant data to a receiver that saves
the data for each panel. Post identification data can also be
collected automatically or manually. Each post sleeve can be
provided with a unique bar code identifier or RFID tag that the
user scans to enter.
[0091] The user sends the data for the fence to a central data
repository and/or a manufacturer, who then manufactures all of the
panels, marks each panel with the appropriate information to
identify the post sleeves supporting the posts between which it
will be attached, and ships the panels back to the user. The
manufacturer may also cut posts to the correct lengths and ship
those, as well. The user then correlates the markings on the posts
and panels to the unique identifier of the post sleeves, and then
places the fence posts in the corresponding post sleeves and
installs each fence panel between the designated pair of posts.
[0092] As the data is collected, it may be immediately uploaded to
the repository or manufacturer via a cellular or web connection,
allowing production of the panels to begin as the sleeves are being
installed.
[0093] The positions and spacing of the fence posts may be
determined in advance, and the fence panels are preordered. In this
case, the user installs the post sleeves from a specific plan, and
positions the posts precisely as required to receive the panels. In
such a case, it becomes necessary to perform at least a basic
survey of the property to establish overall dimensions and
elevations. In a similar way, a user can install mass-produced
fence panels at their standard spacing.
[0094] Post positioning systems have been disclosed that employ
spider frames with adjustable legs for positioning post sleeves.
However, in some instances, a motorized system may be provided in
lieu of adjustable legs or other structures, which is
self-propelling, using wheels, or tracks similar to those of a
bulldozer, and that includes a post sleeve attachment, as well as
systems for manually or automatically positioning, orienting, and
plumbing a post sleeve. The system can be configured to be operated
by direct or remote control of an operator, or to be preprogrammed
so as to move automatically from one position to the next, guided
by GPS, or by reference to a fixed position, such as a transmitter
or a surveyor device, or by other known systems or methods.
[0095] FIGS. 9 through 15 illustrate embodiments including post
sleeve installation devices and spacing beams that can be coupled
to one another to form a post sleeve positioning system in which
the spacing beam can be oriented at any angle with respect to the
post sleeve installation devices. Thus, in the post sleeve
positioning systems illustrated in FIGS. 9 through 15, the spacing
beam need not be level during use, and rather can be oriented at
any desired pitch or incline. FIGS. 9 and 10 illustrate an
embodiment of a spider frame or post sleeve installation device 500
for use in a post sleeve positioning system. With the exception of
the features of the post sleeve installation device 500 described
herein, the post sleeve installation device 500 can comprise
components and features similar or identical to those of the post
sleeve installation devices or spider frames 202 described above
with reference to FIGS. 2 through 8. FIGS. 11 through 15 illustrate
another embodiment of a spacing beam 600 for use with the post
sleeve installation device 500 (or a plurality of post sleeve
installation devices 500) in a post sleeve positioning system. With
the exception of the features of the spacing beam 600 described
herein, the spacing beam 600 can comprise components and features
similar or identical to those of the spacing beam 204 described
above with reference to FIGS. 2 through 8.
[0096] As shown in FIG. 9, the post sleeve installation device 500
can include three legs 502 having components and features similar
or identical to those of the legs 214 described above with
reference to FIGS. 2 through 8. For example, the legs 502 can
include adjustable feet 504 by which the post sleeve installation
device 500 can be positioned level over a post hole regardless of
the terrain. Using three legs 502 rather than four legs 214 can
simplify the post sleeve installation device 500, thereby reducing
expense, and can simplify the process of levelling the post sleeve
installation device 500 over a post hole. The post sleeve
installation device 500 also includes a Z-axis spacer 506 similar
to the Z-axis spacer 226 described above with reference to FIGS. 2
through 8.
[0097] As shown in greater detail in FIG. 10, the post sleeve
installation device 500 also includes a coupling assembly 508
coupled to the top end portion of the Z-axis spacer 506, which can
be used to couple the post sleeve installation device 500 to one or
more spacing beams 600. The coupling assembly 508 can include a
central vertical extension shaft 510 coupled to and extending
vertically away from the top of the Z-axis spacer 506, and a
central coupling shaft 514 coupled to and extending vertically away
from the top end portion of the vertical extension shaft 510. The
coupling assembly 508 can also include a plurality of peripheral
coupling shafts or protrusions 512 coupled to and extending
vertically away from the top of the Z-axis spacer 506.
[0098] The coupling assembly 508 is shown in FIGS. 9 and 10 as
having three coupling shafts 512, but can include four peripheral
coupling shafts 512 that are equidistantly spaced apart from one
another around the vertical extension shaft 510, and that can be
positioned to correspond to four surfaces of a square orifice of a
post sleeve to be installed using the post sleeve installation
device 500. The peripheral coupling shafts 512 can be coupled to
the top of the Z-axis spacer 506 at respective locations forming
the corners of a square. The peripheral coupling shafts 512 can be
coupled to the top of the Z-axis spacer 506 at respective locations
spaced apart from one another by 90.degree. along a circle having a
center coincident with the central longitudinal axis of the
vertical extension shaft 510. In other implementations, the
coupling assembly 508 can include any suitable number of coupling
shafts, such as a single one or exactly two, three, five, six,
eight, or more coupling shafts.
[0099] The coupling shafts 512 and 514 can have any suitable
cross-sectional shape(s), such as circular, oval, elliptical,
triangular, rectangular, square, pentagonal, or other
cross-sectional shapes. In some embodiments, however, it can be
particularly advantageous for the coupling shafts 512 and 514 to
include upper cylindrical portions 512a, 514a having circular
cross-sectional shapes, and lower base portions 512b, 514b having
shapes including truncated spheroids. For example, each of the
lower base portions 512b and 514b can have a shape including a
prolate spheroid that is truncated at its top, where it meets the
upper cylindrical portion 512a or 514a, and truncated at each of
its four sides 512c or 514c. Thus, the base portions 512b and 514b
can taper from a relatively wide bottom end, having a
cross-sectional shape comprising a square or a square with rounded
corners, upward toward a top end having a cross-sectional shape
comprising a circle matching the circular cross-sectional shape of
the upper cylindrical portion 512a or 514a. In some
implementations, the coupling assembly 508 includes a cylindrical
rod 516 seated between an upward facing semi-circular groove in the
top of the Z-axis spacer 506 and a downward facing semi-circular
groove in the bottom of the coupling shafts 512. The cylindrical
rod 516 can have a central longitudinal axis that is perpendicular
to, and that intersects with, a central longitudinal axis of the
Z-axis spacer 506 such that it points toward the center of the post
sleeve installation device 500. An additional advantage provided by
the cylindrical rod 516 is described further below.
[0100] The vertical extension shaft 510 has a square
cross-sectional shape, but in other implementations can have any
suitable cross-sectional shape. The edges of the square
cross-sectional shape of the vertical extension shaft 510 are
aligned with or substantially parallel to the edges of the square
cross-sectional shapes of the bottoms of the coupling shafts 512
and 514, and all of these edges can be spatially representative of
a square post to be installed within a square post sleeve installed
using the post sleeve installation device 500. The coupling shaft
514 has a central longitudinal axis coincident with a central
longitudinal axis of the vertical extension shaft 510, which is
coincident with a central longitudinal axis of the Z-axis spacer
506, which can also be coincident with a central longitudinal axis
of a post sleeve when the post sleeve is coupled to the post sleeve
installation device 500. The coupling shafts 512 can have
respective central longitudinal axes that are parallel to the
central longitudinal axis of the Z-axis spacer, and that are offset
from the central longitudinal axis of the Z-axis spacer by
well-defined distances. The coupling shafts 512 and 514 can be
positioned at well-defined elevations above a post sleeve when the
post sleeve is coupled to the post sleeve installation device
500.
[0101] FIG. 11 illustrates that the spacing beam 600 can include a
telescoping main body 602, a first end 604, and a second end 606
spaced apart from the first end 604 across the length of the main
body 602. The spacing beam 600 can also include a controller 608
mounted to the top of the main body 602 and a power supply 610
mounted to the bottom of the main body 602. FIG. 12 illustrates
some components of the spacing beam 600, including the first end
604 of the spacing beam 600, in greater detail. As shown in FIG.
12, an end of the main body 602 can be coupled to a knuckle portion
612 at a hinge 614, and the knuckle portion 612 can be coupled to a
rotatable member 616 at a joint 618.
[0102] The first end 604 of the spacing beam 600 can be configured
such that, when the spacing beam 600 is in use, a pivot axis
A.sub.1 or central longitudinal axis of the hinge 614 is horizontal
and perpendicular to a central longitudinal axis of the main body
602, and such that a pivot axis A.sub.2 or central longitudinal
axis of the joint 618 is vertical and perpendicular to the pivot
axis of the hinge 614. Thus, when the spacing beam 600 is in use,
the joint 618 can allow the main body 602 to rotate horizontally or
yaw about a vertical axis A.sub.2, and the hinge 614 can allow the
main body 602 to rotate vertically or pitch up and down about a
horizontal axis A.sub.1. The joint 618 can include a radial or
rotary encoder that measures the angular position of the knuckle
612 with respect to the rotatable member 616 and outputs an analog
or digital signal corresponding to this angular position, which can
also correspond to a bearing of the main body 602. The hinge 614
can also include a radial or rotary encoder that measures the
angular position of the knuckle 612 with respect to the main body
602 and outputs an analog or digital signal corresponding to this
angular position, which can also correspond to a slope of the main
body 602. The telescoping main body 602 can also include a linear
encoder that measures the length of the main body 602 along a
longitudinal axis X, based on the relative positions of an inner
body 602a and an outer body 602b of the main body 602 (see FIG.
11), and outputs an analog or digital signal corresponding to this
length. The encoders described herein can be absolute or
incremental encoders.
[0103] The second end 606 of the spacing beam 600 can have
components and features corresponding to and matching those of the
first end 604 of the spacing beam 600, or otherwise similar
thereto. In some cases, the second end 606 includes a radial or
rotary encoder in its hinge or joint to act as a check on the
measurement from the encoder in the hinge 614 and/or joint 618. In
other instances, the second end 606 does not include an encoder in
its hinge or joint to reduce expense and complexity.
[0104] FIG. 13 shows the bottom of some of the components of the
example embodiment of the spacing beam 600 shown in FIGS. 11 and
12. For example, FIG. 13 shows that the rotatable member 616
includes an opening or mouth 620 to an internal cavity 622 of the
rotatable member 616. The opening 620 can have shape comprising a
square or a square with rounded corners that matches the shape of
the bottom of the coupling shafts 512 and 514. The internal cavity
622 can have a circular cross-sectional shape that matches the
cross-sectional shape of the upper cylindrical portions 512a, 514a
of the coupling shafts 512 and 514. Thus, the opening 620 and
internal cavity 622 of the spacing beam 600 can be snugly mated or
coupled to one of the coupling shafts 512 or 514 of the post sleeve
installation device 500, such that the rotatable member 616 is
rotationally locked to the post sleeve installation device 500. A
central longitudinal axis of the opening 620 can be coincident with
a central longitudinal axis of the cavity 622, as well as with a
central longitudinal axis of the rotatable member 616 and an axis
of rotation of the joint 618. The opening 620 can also include a
downward-facing semi-circular groove 621 having a central
longitudinal axis that intersects, and that is perpendicular to,
the central longitudinal axis of the rotatable member 616 and the
axis of rotation of the joint 618. The groove 621 can snugly mate
with the portion of the cylindrical rod 516 that extends above the
top of the Z-axis spacer 506.
[0105] FIG. 13 also shows a gasket 624 between a knuckle extension
602c and the outer body 602b of the main body 602. The gasket 624
can be coupled to the main body 602 to seal the knuckle extension
602c to the outer body 602b. A plug 630, illustrated in an
unplugged configuration to more clearly illustrate its features,
can be coupled to the gasket 624 or formed integrally therewith,
and can be used to plug a jack of the power supply 610 when the
power supply 610 is not in use, such as to prevent or reduce the
ingress of contaminants through a connector of the power supply
610.
[0106] FIGS. 14 and 15 show the controller 608. The controller 608
can include a power button 634, and can include internal circuitry
to receive power from the power supply 610 and to receive the
signals corresponding to the angles of rotation of the hinges 614
and the joints 618, and to the length of the main body 602, of the
spacing beam 600. The controller 608 can also include a central
processing unit and a display positioned at 632 to process the
signals and output results of the processing to a user. For
example, based on the signals received by the controller 608, the
controller 608 can compute x-, y-, and z-coordinate distances
(e.g., north-south, east-west, and elevation coordinate changes)
between a first post sleeve coupled to a first post sleeve
installation device 500 coupled to the first end 604 of the spacing
beam 600 and a second post sleeve coupled to a second post sleeve
installation device 500 coupled to the second end 606 of the
spacing beam 600.
[0107] In some implementations, based on the signals received by
the controller 608 and using geometry and trigonometry, the
controller 608 can compute a distance, bearing, and elevation
change between two post sleeves. The display can present numbers to
a user, such as a horizontal distance 636 between two post sleeves
and a change in elevation 638 between the two post sleeves, which
can be signed to indicate whether the spacing beam is oriented
uphill or downhill. As an example, a positive change in elevation
638 can indicate that the first end 604 of the spacing beam 600 is
located at a higher elevation than the second end 606 of the
spacing beam 600. The controller 608 can also include a light 640
that lights up when the spacing beam 600 is closer to level than an
acceptable threshold amount.
[0108] The results can be output to a user visually at the display
positioned at 632, and the controller 608 can also include USB
port, Bluetooth and WiFi hardware and software, or other wireless
communication devices, to communicate the results to a mobile
computing device, such as a laptop computer or a smart phone. For
example, FIG. 16 shows a photograph of a user interface of a cell
phone for use with the systems described herein, and illustrates
that the user interface can display a length and height distance
between two adjacent fence post sleeves, the tilt and angles
measured by the inclinometer and encoders discussed herein,
latitude and longitude coordinates for the location, and a time the
measurement was taken. The mobile computing device can relay the
information to a database stored at any location, such as over the
internet or other network. The controller 608 can also include a
highly sensitive and highly accurate inclinometer that senses the
slope of the main body 602 of the spacing beam 600, a compass, and
Global Positioning System ("GPS") hardware and software that can
obtain the location of the controller 608.
[0109] A signal generated by the inclinometer can be used as a
check of or as a replacement for the signal from the rotary encoder
corresponding to the slope of the main body 602. In some cases, the
signal from the rotary encoder corresponding to the slope of the
main body 602 (e.g., from a rotary encoder at the hinge 614) can be
compared to the signal generated by the inclinometer and a
difference between these two measurements can indicate a degree to
which a post sleeve installation device 500 coupled to the main
body 602 (e.g., by the hinge 614) is out of plumb. In particular,
the signal from the inclinometer can indicate the true slope of the
main body 602 and the difference between the measurements can
indicate the degree to which the post sleeve installation device
500 deviates from vertical. The measurement of the degree to which
the post sleeve installation device 500 is out of plumb can be used
by an installer to plumb the post sleeve installation device (e.g.,
by adjustment until this measurement is zero) or can allow a fence
panel manufacturer to manufacture fence panels to be installed
using out-of-plumb post sleeves.
[0110] A signal generated by the compass can be used to determine a
bearing of the main body 602, such as to provide a check of the
signal from the rotary encoder corresponding to a bearing of the
main body 602. The signals from the rotary encoders corresponding
to the bearing and slope of the main body 602, the compass data,
and/or the GPS data can be used to display the location and bearing
of a software-developed fence system or the main body 602 and post
sleeve installation devices 500, or post sleeves installed in the
ground on a map of the region where the fence is to be installed.
The controller 608 can also include a thermometer that can output a
signal corresponding to an environmental temperature, which can be
used to compensate, when computing measurements, for changes to
dimensions of components of the system resulting from changes in
the environmental temperature at the time of installation.
[0111] Methods of using a post sleeve positioning system including
a plurality of post sleeve installation devices 500 and the spacing
beam 600 can be similar to other methods described elsewhere
herein. In one example method, a user can use a first post sleeve
installation device 500 to position and install a first post
sleeve. The user can then determine the absolute location of the
first post sleeve, such as by using the GPS components of the post
sleeve positioning system, a separate GPS device, or by traditional
survey methods. The user can then use a second post sleeve
installation device 500 to position a second post sleeve. The user
can then use a first spacing beam 600 to measure the relative
locations of the first and second post sleeves, and can adjust the
location of the second post sleeve until the user determines, using
the first spacing beam 600, that the relative locations of the
first and second post sleeves are suitable. The user can then
install the second post sleeve and record the relative locations of
the first and second post sleeves, and thus also the absolute
location of the second post sleeve. Data representing any of the
raw measurements described herein, and/or the relative locations of
the first and second post sleeves, can be communicated from the
controller 608 to the mobile computing device, and from the mobile
computing device to the database, or from the controller 608
directly to the database.
[0112] The method can progress and the steps can be repeated in any
suitable order. For example, a user can use a third post sleeve
installation device 500 to position a third post sleeve, and the
user can then use the first spacing beam 600 or a second spacing
beam 600 to measure, adjust if necessary, and record the relative
locations of the second and third post sleeves. Alternatively, the
user can remove the first post sleeve installation device 500 from
the first post sleeve and use the first post sleeve installation
device 500 to position a third post sleeve, and then use the first
spacing beam 600 or a second spacing beam 600 to measure, adjust if
necessary, and record the relative positions of the second and
third post sleeves.
[0113] In another example method, a user can use a post sleeve
installation system including a plurality of post sleeve
installation devices 500 and the spacing beam 600 to position post
sleeves at predetermined locations. For example, the user can
couple a first post sleeve to a first post sleeve installation
device 500 and use the post sleeve installation system and GPS
components included therein, a separate GPS device, or traditional
survey methods to position and install the first post sleeve at a
predetermined location to within suitable tolerances. The user can
then couple a second post sleeve to a second post sleeve
installation device 500 and couple the spacing beam 600 to the
first and second post sleeve installation devices 500. The user can
then use the output provided by the controller 608 to adjust the
position of the second post sleeve until the position of the second
post sleeve matches a predetermined location for the second post
sleeve to within suitable tolerances. The user can repeat these
steps in any suitable order for any desired number of post
sleeves.
[0114] If the user encounters an especially steep grade such that
the vertical rotation of the spacing beam 600 allowed at the hinge
614 is insufficient to accommodate the change in elevation between
two adjacent post sleeve installation devices 500, then the user
can couple one end of the spacing beam 600 to a coupling shaft 512
of the higher of the two post sleeve installation devices 500 and
the other end of the spacing beam 600 to the coupling shaft 514 of
the lower post sleeve installation device 500. The vertical
extension shaft 510 can have well-defined dimensions including a
well-defined height, such as a height of six inches, and can act as
a vertical offset to allow a post sleeve installation system to
traverse steeper grades than would be allowed without the vertical
extension shaft 510. The user can provide input to the controller
608, e.g., manually or via a sensor trigger on the coupling shaft
514, to indicate that the system is being operated in such a
manner, so the controller can modify its geometric or trigonometric
calculations accordingly.
[0115] If the user couples multiple spacing beams 600 to one post
sleeve installation device 500, the user can couple the spacing
beams to any suitable combination of the coupling shafts 512 and
514. For example, to install post sleeves for fence posts of a
single fence run, the user can couple a first spacing beam 600 to a
first coupling shaft 512 and a second spacing beam 600 to a second
coupling shaft 512 opposite to the first coupling shaft 512 across
the vertical extension shaft 510, which can be representative of
opposing sides of a fence post to eventually be installed in that
location, such that two of the coupling shafts 512 are spaced apart
from one another by 180.degree.. As another example, to install
post sleeves for fence posts at a location where one fence run
meets another (e.g., at a corner of a fence), the user can couple
spacing beams 600 to coupling shafts 512 of a fence post
installation device 500 spaced apart from one another by
90.degree., which can be representative of adjacent or
perpendicular sides of a fence post to eventually be installed in
that location. As another example, to install post sleeves for
fence posts at a location where one fence run intersects another
fence run, the user can couple spacing beams 600 to three or four
of the coupling shafts 512 of a fence post installation device
500.
[0116] A post sleeve installation system kit can include a
plurality of fence post installation devices 500 and/or a plurality
of spacing beams 600. For example, a kit can include exactly two
fence post installation devices 500 and exactly one spacing beam
600. As another example, a kit can include multiple post sleeve
installation devices 500 and multiple spacing beams 600, such as 5
to 8 post sleeve installation devices 500 and 3 to 5 spacing beams
600. In some cases, a kit can include multiple spacing beams 600
having different nominal lengths from one another, such as a first
spacing beam having a minimum length of 33 inches and a second
spacing beam having a maximum length of 96 inches. Providing a kit
with spacing beams 600 of different nominal lengths can facilitate
the placement of post sleeves at the ends of fence runs and in the
region of gates in a fence run. In other cases, a kit can include
multiple spacing beams 600 having different sensor configurations,
such as three spacing beams 600 including the a radial encoder at
the respective joints 618 and three spacing beams 600 not including
a radial encoder at the respective joints 618, such as for use in
installing straight fence runs.
[0117] Once a post sleeve is positioned within a post hole, the
hole can be initially only partially back-filled using a
fast-setting concrete, expansion foam, or other formulation of a
hardenable material, so that the post sleeve installation devices
500 can be moved more quickly. A user can return later to finish
back-filling the hole with a concrete formulation, expansion foam,
or other hardenable material that is selected for strength and
weatherability rather than setting speed. A first partial footing
can be configured to set very quickly, with sufficient strength to
hold a respective post sleeve in place, to permit the user to work
more quickly using fewer post sleeve installation devices 500.
Further, the material of the partial footing can be configured to
have a selected porosity to permit water that enters the sleeve to
percolate from the sleeve into the ground at a controlled rate.
[0118] Various devices and methods have been described for
obtaining data regarding the relative positions of post sleeves,
including elevation, orientation, and distance apart. It should be
noted that in some cases, the only information necessary is
distance and elevation, or even distance, alone. For example, if a
fence is to include only straight lines and right angles, and the
posts are to be square and aligned with the fence line, every fence
panel will be perpendicular to the faces of the posts to which it
is attached. Thus, orientation of each post need not be measured.
This is also true if the posts are to be round, regardless of the
path followed by the fence line. Likewise, if the fence is to
follow a substantially level line, elevation need not be measured.
Thus, while various implementations enable the collection and
transmission of many classes of data, the scope of the claims also
encompasses implementations in which only limited data is collected
or transmitted.
[0119] Many of the disclosed implementations can be adapted for use
with other post support mechanisms, such as, for example, post
brackets, which are sometimes used to attach posts to existing
surfaces. Furthermore, even in cases where posts are set in the
ground by conventional means, without sleeves, custom fence panels
can be manufactured as disclosed, if the necessary data is
collected and transmitted to the manufacturer.
[0120] According to various implementations, as discussed above,
data related to the positioning of the post sleeves of a fence are
collected for use by a fabricator to make fence panels or kits in a
factory environment that are "custom-made" for that fence.
According to another implementation, a central data archive is
provided, to which the data is also sent. By collecting and storing
such information, it is preserved for access at any time in the
future. For example, if a portion of a fence is damaged, the
information is available to produce replacement panels with the
same style, material, and finish as the original fence, even if the
fence is a one-of-a-kind design. Any properly equipped fabricator
can use the previously stored data to manufacture replacement
panels that will perfectly match the original design. Furthermore,
when a fence is to be completely replaced, it is not necessary to
obtain new data unless the location of the fence also changes.
Otherwise, new posts can be placed in the original post sleeves,
meaning that the original data will still be valid.
[0121] Ideally, the central archive collects data from a very large
geographical region, e.g., nationally. However, a number of
different facilities can collect the information for respective
smaller geographical areas, as well, such as by state or county.
Archives can be maintained by any of a number of different
entities, including, for example, local or national trade groups,
for-profit companies, local governments or extension services,
fabricators themselves, etc.
[0122] Nevertheless, there are some benefits that are obtained from
centralized collection of the information. For example, statistical
data can be obtained for evaluation of performance and durability
of different post sleeve designs, materials, and installation
methods, over extended periods, in many different environments.
Also, with plural archives, it may be at times difficult to locate
data for a given fence. Controlling entities can move or go out of
business or consolidate; competing manufacturers could be reluctant
to share data, etc. In contrast, if there is one central archive,
there is never a problem locating the data, and it is more likely
to remain current.
[0123] A fence installation process can be provided. Initially, a
piece of property is surveyed and the property lines are defined.
This can be in conjunction with the subdivision of a larger parcel,
or by a developer who surveys all the lots of a housing
development, etc. The locations of post sleeves are then
determined. According to one implementation, a software program is
provided that is configured to automatically select the positions
and spacing of the post sleeves on the basis of the plot plan or
survey data, and preferences entered by a user. For example, the
user can define the maximum distance between posts or the maximum
length of fence rails, and can select the locations of gates, runs,
etc., which are shown on a site map that can be printed out for use
by the installer. If the post sleeve installation system is
configured to employ a post-to-post spacing format, like that
described with reference to FIGS. 2-8, the locations of the fence
and main posts are marked on the property by referring to the site
map. The markings are general in nature, e.g., a string line, laser
line, stakes, GPS, etc., to assist in initial positioning of the
post holes and main post sleeves. The post holes are then dug and
the sleeves are installed. Although the installer works from the
site map and spacing previously set forth, the actual position and
orientation of each post sleeve, relative to the adjacent sleeves,
is determined and recorded by the installer. This ensures that
small deviations from the prescribed positioning are recorded, so
the fence panels will fit properly.
[0124] The post sleeves may be installed before other construction
is begun, and perhaps even before the property is fully graded. The
installer positions the post sleeves relative to the desired finish
elevation, even if the ground where the post sleeves are installed
is not yet at the finish grade level. In such a case, the
contractor may thereafter use the pre-positioned post sleeves as
markers when finish grading the property. This means that
particular sleeves may be installed some distance above or below
the current grade. To install below grade, of course, the installer
merely digs a deeper post hole and places the sleeve at the correct
level. To install more than a few inches above grade, the installer
can use a commercially available concrete form (e.g., a
Sonotube.RTM. form) to make a short column in which the sleeve is
embedded. The sleeves can be capped to prevent dirt from falling
inside, or marker flags can be placed in the sleeves so the graders
can see them, for reference, and to avoid damaging them. The
sleeves are positioned so that, when the property is at the finish
grade, the sleeves (capped) are a few inches above the surface and
ready to receive posts.
[0125] During installation of the post sleeves, information
necessary for manufacture of the panels is collected, either
automatically or manually, depending on the installation system
used. This information is sent to a central archive, where it is
assigned a file number and stored. The information provided by the
post sleeve installer includes the locations of all of the post
sleeves on the property, their relative positions and orientations,
and the unique identifier of each sleeve. Additional information
that can be provided includes, for example, the sleeve model and
manufacturer, the grade of concrete used to install the sleeve,
provisions made for drainage, depth of concrete, hole diameter,
relative heading from neighboring sleeves, GPS coordinates,
installation date, the installing contractor, and the current
property owner. All of the measured GPS coordinates can be
cross-referenced using the other measurements taken during
installation to improve the overall accuracy of the GPS
coordinates.
[0126] When a property owner, contractor, or developer is ready to
install a fence, they can go to an internet-connected software
system and input the relevant address. The program can search for
stored data and render the 3-D post sleeve installation locations
in a rotatable user interface. The user can then select from lists
of options a fence material such as vinyl, a style such as lattice
top, a minimum and a maximum height of the fence to allow the fence
to follow a contour of the land, and a method by which the top of
the fence would traverse the topography such as stair step,
topography-following, concave, or convex finish. The software can
render and price the fence system as the user makes selections and
adapts the model to their liking. Once the user is satisfied, the
user can consummate a sale and an order can be processed over the
internet to the closest properly equipped manufacturer for
manufacture of the fence and post system components. As the fence
panels and posts are produced they can be marked with unique
identifiers of the sleeves they are to be installed with, and the
components can be shipped to the relevant address for installation
or to an installer.
[0127] An installer removes storage caps from the tops of the
sleeves, and places the posts in the corresponding sleeves, then
attaches each panel to the appropriate posts, referring to the
markings placed by the manufacturer on the fence components and the
unique identifier of each post sleeve to correctly position each
post and panel. The fence components can be installed by a
contractor working for the developer or property owner, or a
reasonably handy property owner can do the installation,
unassisted.
[0128] In cases where the fence is installed by a developer when
the property is first subdivided and developed, installation may be
days, weeks, or months after installation of the post sleeves. The
developer may install fence panels only along property lines around
the perimeter of a development, while leaving the remaining post
sleeves unoccupied but covered with form-fitting storage caps. If
fences are not installed by the developer, some who later purchase
lots may elect to install fences, while others may not. However,
even years later, a second or third owner can choose to install a
fence, and the sleeves will be waiting and the data still available
at the archive. Furthermore, because the sleeves are installed
according to the original survey when the property is subdivided,
they can appear on later survey maps and in the legal description
of the property, and can be used as visual reference markers to
correctly define boundaries thereafter. Thus, installing the post
sleeves can enhance the value of the property and assist in the
sale of the original property by visually defining the property
lines, regardless of whether a fence is actually installed at that
time.
[0129] When an individual purchases a lot, the data is already on
file, and the owner can consult with a contractor, a fabricator, or
refer to a website such as the one described above to select a
fence design, materials, finish, etc. The user can provide a file
number or other information to identify the specific property, and
the consultant or website software can then download the pertinent
data from the central archive and produce a rendering of the
property's installation locations, showing a fence in the selected
design, or showing various options for the user to choose from. The
software can allow the user to order a finished panel and post
system or a do-it-yourself kit including the components and plans
needed to build the panels on-site. Once the user has made a
selection, the order can be placed immediately, by any appropriate
means, including by telephone, email, web order, etc.
[0130] When a customer orders fence panels, a software system can
automatically download the necessary data a fabricator's
optimization and assembly system. If the fence style is one of a
number of designs that are offered as standard by the fabricator,
and if the extent of the data downloaded from the central archive
is relative post sleeve positions, information specific to that
style can be already present in the system, so that when an
operator enters the information specific to the post sleeves of the
customer's property, the system automatically calculates the
numbers and dimensions of all the individual parts of each panel to
be manufactured.
[0131] At any given time, the fabricator may have dozens of fence
orders in queue. Lumber enters the system in random length boards
according to the lengths of the stems from which they were milled,
or as mill shorts. The system carries a running list of material
yet to be cut for all the pending orders. As each board is fed into
the machinery, the system scans it to determine its dimensions and
to detect flaws, then calculates which of the list of pieces can be
cut from the board to result in the least amount of waste, cutting
the board accordingly. The system can also be configured to
consider the structural strength necessary for a given piece. Thus,
for example, a rail that will eventually span between two posts and
support much of the weight of the panel, as well as wind load,
etc., may need to be substantially clear of knots and checks, while
a slat of a lattice, which will never be required to support more
than a minimal load, can have a number of structural flaws,
provided they don't detract from its appearance.
[0132] After cutting, each piece can be marked with a code that
indicates the job, panel, and component, and is then sorted, at
least by job. Marking can be by any of a number of known means,
including stamping, laser, spray, RFID, etc. Alternatively, an
inline sorting and tracking system can be enabled to memorize each
component track through the assembly process without visual
markings.
[0133] One of the fence rails of each panel is also marked at each
end with the unique identifier of the respective post sleeves
between which that panel is to be installed. The fence posts are
also marked with unique identifiers after they are cut to length.
During installation, the installer will refer to these markings to
determine the location of the particular posts and panels. If
necessary, the marked portions can be covered by a clear wax or
finish to prevent stain or paint that is later applied from
obscuring the markings.
[0134] According to one implementation, assembly workers assemble
all the components of each panel, referring to the markings to
correctly assemble the components. The markings can be in a
computer-readable format, such as bar codes, so that if a worker is
unsure of where a particular piece of material belongs, its marking
can be passed under a reader, and the system will indicate the
panel and location of the piece. According to another
implementation, the system automatically assembles at least
portions of some or all of the panels, with workers doing final
assembly. According to yet another implementation, in cases like
continuous extrusion of vinyl fencing, a flying bridge saw can cut
each piece of a desired fence panel in a continuous line being
managed by a pick-and-place robot assembling the panels enabling a
zero waste environment where even the vinyl shavings are returned
back to the extrusion process for reuse.
[0135] Either before or after assembly of a wood fence, the
components of the fence can be factory-finished, by dipping or
spraying each component with a stain or paint finish selected by
the customer. Once the finish has cured, the components are crated
or banded for shipment. The panels and posts are preferably stacked
and banded in order of position in the finished fence line, so that
the installer can place a stack of panels on a cart or flatbed
truck and, moving along the fence line, drop the correct panel and
post at each position, in order. In most cases, there will be
little or no waste at the fence site, apart from packing material,
which itself will be minimal.
[0136] Over time, fence posts and panels will be damaged or will
deteriorate. Replacement panels can be easily obtained using the
system. Either the property owner or the manufacturer can obtain
the data from the repository, including style, material, finish,
and possibly detailed scaled images of the installed product during
production. The customer merely indicates which panels and which
posts need to be replaced, and the manufacturer can produce an
identical panel from the original data, which is then shipped to
the customer. If a single unique fence board needs to be replaced,
it is possible to cut an exact match and ship the replacement. If
posts need to be replaced, the old posts are pulled from the
sleeves, which are then cleaned, if necessary, and the new posts
are dropped in. The panels are then installed as previously
described.
[0137] While fabrication of wood panels is described above, other
materials, such as, but not limited to, plastics and metal, can
also be processed similarly. This is especially true where, because
of normal operations in related or unrelated industries, there is a
surplus of materials that are normally scrapped, but that could be
used in fence panels.
[0138] According to an implementation, the end consumer accesses a
software program that provides all the necessary tools to select a
fence design and place an order. The program may be accessed, for
example, via the internet, at a retail location, or with the
assistance of a contractor. The user can input an address or some
other identifier such as tax lot number etc. If data related to
that property is present in the central repository or in other
accessible records, the program then populates with a 2- or
3-dimensional rendering of the property, according to the
information and detail that is available. The rendering includes
the current fence or previously installed post sleeves. The user
selects materials, color and finish, style, and other details, all
of which are displayed and described in the rendering, as they are
selected. Information about manufacturers is provided, such as
delivery times and prices. A running subtotal of the cost of the
fence is provided, together with costs (or estimates) of delivery,
installation, and tax, together with a total cost. The user is thus
able to select and order a fence according to personal criteria,
without outside assistance or interference, or whatever level of
assistance or advice is desired. Once an order is placed, the
system updates the central repository accordingly.
[0139] In a similar fashion, a user can select and order an
individual replacement panel, inputting the unique identifier or
identifying the particular panel from the 3D model or stored
pictures. Additionally, the consumer can log on to the website, or
otherwise access the system from time to time, to update the
database to reflect changes, e.g., new stain colors, contractors
used, etc., or to access the actual plot plan for future
reference.
[0140] While devices configured for use in installing post sleeves
may be recited in the claims, unless specifically recited as an
element, post sleeve is not to be read as a claim limitation, i.e.,
if a claim reads on a device with a post sleeve attached, it will
also read on the same device without the post sleeve.
[0141] References in the specification and claims to movement in or
parallel to ordinal axes, such as the X, Y, or Z axis, do not refer
to specific axes, but to three mutually orthogonal axes, except
that reference to the Z axis can be understood as referring in
particular to a vertical axis, while X and Y axes can be understood
as lying in a horizontal plane. Reference to orientation is to be
understood as referring to an angle of rotation around a vertical
axis.
[0142] The term position refers to the location of an element in
three orthogonal axes, unless explicitly limited further.
[0143] The term post is used in the specification and claims in
relation to a vertical support member, such as is used, for
example, to support a fence or sign, and is not to be construed as
meaning subsequent to.
[0144] The term post bracket is used as a generic term to refer to
hardware configured to support a post at or above a surface,
including, for example, a bolt pattern plate, a "U" bracket, a pier
bracket, and a post bracket. The term post receiver is used in the
claims to refer generically to structures configured to receive and
support a post, including, for example, prefabricated post sleeves,
post brackets, and poured-in-place post sleeves (made using a post
hole mold).
[0145] Adjustments made before coupling the post sleeve to a device
can be read as adjusting the post sleeve. The abstract of the
present disclosure is not intended as a complete or definitive
description of any embodiment thereof, nor should it be relied upon
to define terms used in the specification or claims. The abstract
does not limit the scope of the claims.
[0146] Features and aspects of the various embodiments described
above can be combined, and further modifications can be made, to
provide further embodiments. All of the U.S. patents, U.S. patent
application publications, U.S. patent applications, foreign
patents, foreign patent applications and non-patent publications
referred to in this specification and/or listed in the Application
Data Sheet, including U.S. Pat. Nos. 7,861,434 and 8,011,149, U.S.
Provisional Patent Application No. 62/306,988, filed Mar. 11, 2016,
and U.S. patent application Ser. No. 15/453,725, filed Mar. 8,
2017, are incorporated herein by reference, in their entireties.
Aspects of the embodiments can be modified, if necessary to employ
concepts of the various patents, applications and publications to
provide yet further embodiments.
[0147] These and other changes can be made to the embodiments in
light of the above-detailed description. In general, in the
following claims, the terms used should not be construed to limit
the claims to the specific embodiments disclosed in the
specification, but should be construed to include all possible
embodiments along with the full scope of equivalents to which such
claims are entitled.
* * * * *